System and Method for Removal of Dents from Wind Turbine Masts

• US 20100294016A1
• Filed: 05/20/2010
• Published: 11/25/2010
• Est. Priority Date: 05/21/2009
• Status: Active Grant

• Current Assignee: Barr Fabrication, L.L.C.
• Original Assignee: Barr Fabrication, L.L.C.
• Inventors: Barr, Hugh C.
• Granted Patent: US 8,245,558 B2
• Time in Patent Office: Days
• US Class Current: 72/429
• CPC Class Codes: B21D 1/08 of hollow bodies made from sheet metal of substantially open bodies B21D1/10 ; flattening hollow objects for transport and reforming B21D51/14
• CPC Class Codes: Y10S 72/705 Vehicle body or frame straightener
• CPC Class Codes: Y10T 29/49748 by shaping, e.g., bending, extruding, turning, etc.

Abstract

A system and method for removal of dents from wind turbine masts uses a dent pushing tool. The dent pushing tool includes a self aligning ram assembly with a central ram cylinder and removable adjustable length arms. At the end of one arm is a curved base. At the end of the other arm is a dent pusher plate. Removal of the dent is caused by extension of the central ram cylinder.

Claims

1. A device for pushing out a dent in a substantially circular hollow metal structural support column from within said hollow metal structural support column, said device comprising:

a self aligning ram assembly, said self-aligning ram assembly including;

a central ram cylinder;

a first and second adjustable length arm extending outwardly from said central ram, said adjustability being effected by the use of inserts at the end of or within said adjustable length arms;

a curved base attached to the outboard end of said first adjustable length arm;

a pusher plate attached to the outboard end of said second adjustable length arm;

wherein said pusher plate is constructed and arranged for placement against the dent, said curved base is constructed and arranged for placement on the inside wall of the structural support column opposite from the dent and the first and second adjustable length arms are substantially aligned with the diameter of the substantially circular hollow metal support column.

2. The device as defined in claim 1 wherein said central ram is an air over hydraulic ram.

3. The device as defined in claim 1 wherein said central ram is an electric over hydraulic ram.

4. The device as defined in claim 2 wherein the operation of the ram is governed by a remote controller.

5. The device as defined in claim 3 wherein the operation of the ram is governed by a remote controller.

6. The device as defined in claim 1 wherein the curved base is substantially arcuate and is formed from a metal which is more flexible than the metal wall of the substantially hollow metal support column.

7. The device as defined in claim 1 wherein the pusher plate is shaped according the shape and orientation of the dent in the wall of the substantially hollow metal structural support column.

8. The device as defined in claim 1 wherein the said first and second adjustable length arms are removable from said central ram.

9. A method for removing a dent from the wall of a substantially circular hollow metal support structural support column, said method comprising the steps of:

measuring the size of the dent;

formulating a plan for removal of the dent;

placement of a dent pushing tool against the dent, said dent pushing tool including;

a self-aligning, remotely actuatable ram assembly including a central ram and first and second adjustable length arms extending from said central ram;

a curved base attached to the end of said first adjustable length arm, said curved base constructed and arranged for placement on the interior wall of the substantially circular hollow metal structural support column across from the dent; and

a dent pusher plate attached to the end of said second adjustable length arm, said pusher late constructed and arranged for placement against the dent on the interior wall of the substantially circular hollow metal structural support column;

aligning said dent pushing tool substantially along an interior diameter of said substantially circular hollow metal structural support column so that said pusher plate is in contact with one end of said dent and said curved base is in contact with the wall interior wall of said substantially circular hollow metal structure across from said dent;

actuating said ram assembly to cause force to be placed on the dent by said pusher plate;

moving said dent pushing tool along the dent from one end to the other and repeating the forgoing procedure until the dent has been removed from the wall of the substantially circular hollow metal structure.

10. The method as defined in claim 9 wherein said step of measuring the dent includes determining the direction of the dent, the size of the dent, the depth of the dent, and the type of the dent.

11. The method as defined in claim 9 wherein said step of formulating a plan for removal of the dent includes determining at which end of the dent to begin the exertion of force against the dent and the locations of where said pusher plate is to be placed against the dent.

12. The method as defined in claim 9 wherein the dent is measured after each application of force against the dent.

13. The method as defined in claim 9 wherein the dent is measured during the dent removal process using one or more non-destructive metal evaluation techniques being selected from a group including surface magnetic particles, ultrasonic testing, electromagnetic wave testing, and strain gauges.

14. The method as defined in claim 13 wherein the plan for removal of the dent is adjusted following each measurement of the dent after each application of force against the dent.

15. The method as defined in claim 9 wherein the area where the dent is measured to verify the removal of the dent.

16. The method as defined in claim 15 wherein force is re-applied to the dent if measurement of the dent indicates that it has not been completely removed.